JP6602523B2 - Insulation material and method for producing insulation material - Google Patents

Insulation material and method for producing insulation material Download PDF

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JP6602523B2
JP6602523B2 JP2013117843A JP2013117843A JP6602523B2 JP 6602523 B2 JP6602523 B2 JP 6602523B2 JP 2013117843 A JP2013117843 A JP 2013117843A JP 2013117843 A JP2013117843 A JP 2013117843A JP 6602523 B2 JP6602523 B2 JP 6602523B2
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insulating material
heat insulating
heat
thermosetting resin
prepreg
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JP2014233935A (en
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喜朗 栗本
茂 中間
和久 渡辺
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Nichias Corp
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Nichias Corp
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Priority to JP2013117843A priority Critical patent/JP6602523B2/en
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Priority to EP14808218.3A priority patent/EP3006806B1/en
Priority to PCT/JP2014/064726 priority patent/WO2014196526A1/en
Priority to US14/895,855 priority patent/US10215325B2/en
Priority to CN202010143737.4A priority patent/CN111457194B/en
Priority to KR1020157034251A priority patent/KR20160014631A/en
Priority to CN201480031919.5A priority patent/CN105339721A/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/028—Composition or method of fixing a thermally insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/067—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B32B38/004—Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/029—Shape or form of insulating materials, with or without coverings integral with the insulating materials layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2701/00—Use of unspecified macromolecular compounds for preformed parts, e.g. for inserts
    • B29K2701/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0082—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B32B2315/085—Glass fiber cloth or fabric

Description

本発明は、断熱材および断熱材の製造方法に関する。   The present invention relates to a heat insulating material and a method for manufacturing the heat insulating material.

使用前に装置形状等に対応する形状に切削加工され、使用状態においては高い強度を要求されるような断熱材、例えば熱プレス、ゴム加硫機や射出成形機の断熱材、誘導炉のケーシングなどに利用される断熱材として、従来より、タルク粉末とパルプをポルトランドセメントで結合した断熱材等が知られていた（特許文献１（特開昭６１−１０９２０５号公報）参照）。   Insulation material that is cut into a shape corresponding to the shape of the device before use and requires high strength in use, such as heat presses, insulation materials for rubber vulcanizers and injection molding machines, casings for induction furnaces Conventionally, a heat insulating material in which talc powder and pulp are bonded with Portland cement has been known (see Patent Document 1 (Japanese Patent Laid-Open No. 61-109205)).

しかしながら、上記断熱材は補強繊維がパルプだけであることから加熱による機械的強度の低下や寸法変化が大きく、断熱材として靱性が不足しているため、切削加工性は良好であるものの高荷重又は衝撃的荷重の付加により亀裂や欠けなどが発生し易かった。   However, since the above-mentioned heat insulating material has only a pulp as the reinforcing fiber, the mechanical strength is greatly reduced and the dimensional change is large due to heating, and the toughness is insufficient as the heat insulating material. Cracks and chips were easily generated due to the impact load.

このため、靱性に優れ、より高い曲げ強度を有するとともに、厚さ精度に優れた断熱材が望まれるようになっていた。   For this reason, the heat insulating material which was excellent in toughness, had higher bending strength, and was excellent in thickness precision came to be desired.

特開昭６１−１０９２０５号公報JP-A-61-109205

従って、本発明の目的は、良好な加工性を有しつつ、耐熱性、機械的強度、靱性等に優れるとともに、加工精度および厚さ精度に優れた断熱材を提供するとともに、該断熱材を簡便に製造する方法を提供することにある。   Accordingly, an object of the present invention is to provide a heat insulating material having excellent workability, excellent heat resistance, mechanical strength, toughness, and the like, and excellent in processing accuracy and thickness accuracy. It is in providing the method of manufacturing simply.

上記技術課題を解決するために本発明者等が鋭意検討した結果、耐熱性ペーパーに熱硬化性樹脂を含浸してなるプリプレグを複数枚積層した状態で熱圧プレス成形されてなる断熱材であって、繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含む断熱材により、上記課題を解決し得ることを見出し、本知見に基づいて本発明を完成するに至った。   As a result of intensive studies by the present inventors in order to solve the above technical problem, a heat insulating material formed by hot press molding in a state in which a plurality of prepregs obtained by impregnating a thermosetting resin into a heat resistant paper is laminated. The present inventors have found that the above problems can be solved by a heat insulating material containing 32 to 64% by mass of a fibrous material and 36 to 68% by mass of a thermosetting resin, and have completed the present invention based on this knowledge. .

すなわち、本発明は、
（１）複数枚のプリプレグのみを積層した積層体からなる断熱材であって、
ガラス繊維の繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含み、
前記プリプレグが耐熱性ペーパーであるガラス繊維製ペーパーへの熱硬化性樹脂含浸物である
ことを特徴とする断熱材、
（２） 前記熱硬化性樹脂の含有割合が５４〜６３質量％であり、前記プリプレグ１枚当たりの平均厚みが０．０５〜３．０ｍｍである上記（１）に記載の断熱材、
（３） 前記プリプレグの積層数が、厚さ１０ｍｍあたり１０〜２００枚である上記（１）または（２）に記載の断熱材、
（４）熱伝導率が０．２５Ｗ／（ｍ・Ｋ）以下である上記（１）〜（３）のいずれかに記載の断熱材、
（５）密度が８００〜１６５０ｋｇ／ｍ３である（１）〜（４）のいずれかに記載の断熱材、
（６） 断熱材を製造する方法であって、
耐熱性ペーパーであるガラス繊維製ペーパーに熱硬化性樹脂を含浸してなる、ガラス繊維の繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含み、平均厚みが０．２〜６ｍｍであるプリプレグのみを複数枚積層し、
前記熱硬化性樹脂の硬化温度以上の温度雰囲気下、熱圧プレス成形する
ことを特徴とする断熱材の製造方法、
（７） 前記熱硬化性樹脂の含有割合が５４〜６３質量％であり、前記プリプレグ１枚当たりの平均厚みが０．０５〜３．０ｍｍになるように熱圧プレス成形する上記（６）に記載の断熱材の製造方法、
（８）前記プリプレグを、得ようとする断熱材の厚さ１０ｍｍあたり１０〜２００枚となるように積層する上記（６）または（７）に記載の断熱材の製造方法、
（９）得られる断熱材の密度が８００〜１６５０ｋｇ／ｍ３である上記（６）〜（８）のいずれかに記載の断熱材の製造方法
を提供するものである。 That is, the present invention
(1) A heat insulating material comprising a laminate in which only a plurality of prepregs are laminated ,
Including 32 to 64% by mass of glass fiber fibrous material and 36 to 68% by mass of thermosetting resin,
A heat insulating material characterized in that the prepreg is a thermosetting resin impregnated material to glass fiber paper which is heat resistant paper,
(2) The heat insulating material according to (1), wherein the content of the thermosetting resin is 54 to 63% by mass, and the average thickness per sheet of the prepreg is 0.05 to 3.0 mm.
(3) The heat insulating material according to (1) or (2), wherein the number of laminated prepregs is 10 to 200 per 10 mm in thickness,
(4) The heat insulating material according to any one of (1) to (3), wherein the thermal conductivity is 0.25 W / (m · K) or less,
(5) The heat insulating material according to any one of (1) to (4), wherein the density is 800 to 1650 kg / m 3 .
(6) A method of manufacturing a heat insulating material,
Glass fiber paper, which is heat-resistant paper, is impregnated with a thermosetting resin and contains 32 to 64% by mass of a glass fiber fibrous material and 36 to 68% by mass of a thermosetting resin. Laminating only a plurality of prepregs of 2 to 6 mm,
A method for producing a heat insulating material, characterized by hot pressing under a temperature atmosphere equal to or higher than the curing temperature of the thermosetting resin;
(7) In the above (6), the content of the thermosetting resin is 54 to 63% by mass, and the hot pressing is performed so that the average thickness per sheet of the prepreg is 0.05 to 3.0 mm. The manufacturing method of the heat insulating material of description,
(8) The method for producing a heat insulating material according to the above (6) or (7), wherein the prepreg is laminated so as to be 10 to 200 sheets per 10 mm thickness of the heat insulating material to be obtained,
(9) The method for producing a heat insulating material according to any one of the above (6) to (8), wherein the density of the heat insulating material to be obtained is 800 to 1650 kg / m 3 .

本発明によれば、良好な加工性を有しつつ、耐熱性、機械的強度、靱性等に優れるとともに、加工精度および厚さ精度に優れた断熱材を提供するとともに、該断熱材を簡便に製造する方法を提供することができる。   According to the present invention, while having good workability, the heat resistance, mechanical strength, toughness and the like are excellent, and a heat insulating material excellent in processing accuracy and thickness accuracy is provided, and the heat insulating material can be easily used. A method of manufacturing can be provided.

本発明の断熱材の構成材料となるプリプレグの製造形態例を示す模式図である。It is a schematic diagram which shows the example of a manufacture form of the prepreg used as the constituent material of the heat insulating material of this invention. 本発明に係る断熱材を製造する一形態例を示す模式図ある。It is a schematic diagram which shows the example of 1 form which manufactures the heat insulating material which concerns on this invention.

本発明の断熱材は、耐熱性ペーパーに熱硬化性樹脂を含浸してなるプリプレグを複数枚積層した状態で熱圧プレス成形されてなる断熱材であって、繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含むことを特徴とするものである。   The heat insulating material of the present invention is a heat insulating material formed by hot press molding in a state where a plurality of prepregs impregnated with a thermosetting resin is impregnated in heat resistant paper, and the fibrous material is 32 to 64% by mass. It contains 36 to 68% by mass of a thermosetting resin.

本発明の断熱材において、耐熱性ペーパーとしては、耐熱性を有する無機ペーパーまたは有機ペーパーを挙げることができる。耐熱性ペーパーが耐熱性を有する無機ペーパーである場合、当該無機ペーパーは繊維状物として無機繊維を含み、耐熱性ペーパーが耐熱性を有する有機ペーパーである場合、当該有機ペーパーは繊維状物として有機繊維を含む。
本発明の断熱材において、耐熱性ペーパーとしては、耐熱性を有する無機ペーパーであることが好ましい。耐熱性を有する無機ペーパーは、バルク状の無機繊維に適宜少量の有機バインダーを加え、抄造機により紙状に加工されるもので、柔軟性に富み、簡単に折り曲げ使用することができるものである。 In the heat insulating material of the present invention, examples of the heat-resistant paper include heat-resistant inorganic paper or organic paper. When the heat-resistant paper is an inorganic paper having heat resistance, the inorganic paper contains inorganic fibers as a fibrous material, and when the heat-resistant paper is an organic paper having heat resistance, the organic paper is organic as a fibrous material. Contains fiber.
In the heat insulating material of the present invention, the heat-resistant paper is preferably an inorganic paper having heat resistance. Heat-resistant inorganic paper is a paper that is processed into a paper-like shape by a papermaking machine by adding a small amount of an organic binder to bulky inorganic fibers. It is flexible and can be easily folded. .

耐熱性を有する無機ペーパーを構成する無機繊維としては、ガラス繊維、シリカ繊維、アルミナ繊維、ムライト繊維、炭化珪素繊維、ロックウール等を挙げることができる。   Examples of the inorganic fiber constituting the heat-resistant inorganic paper include glass fiber, silica fiber, alumina fiber, mullite fiber, silicon carbide fiber, rock wool and the like.

耐熱性を有する無機ペーパーを構成する有機バインダーとしては、アクリル樹脂、ポリビニルアルコール等から選ばれる一種以上を挙げることができる。
なお、耐熱性を有する無機ペーパーは、上記有機バインダーとして熱硬化性樹脂を含む場合もあるが、この場合、断熱材（またはプリプレグ）を構成する熱硬化性樹脂には、上記有機バインダーも含まれるものとする。 As an organic binder which comprises the inorganic paper which has heat resistance, 1 or more types chosen from an acrylic resin, polyvinyl alcohol, etc. can be mentioned.
The inorganic paper having heat resistance may contain a thermosetting resin as the organic binder. In this case, the thermosetting resin constituting the heat insulating material (or prepreg) also contains the organic binder. Shall.

本発明の断熱材において、耐熱性を有する無機ペーパーは、無機繊維の含有割合が４５〜１００質量％であるものが好ましく、７４〜９４質量％であるものがより好ましく、８２〜８８質量％であるものがさらに好ましい。
本発明の断熱材において、耐熱性を有する無機ペーパーは、有機バインダーの含有割合が０〜５５質量％であるものが好ましく、６〜２６質量％であるものがより好ましく、１２〜１８質量％であるものがさらに好ましい。 In the heat insulating material of the present invention, the inorganic paper having heat resistance preferably has an inorganic fiber content of 45 to 100% by mass, more preferably 74 to 94% by mass, and 82 to 88% by mass. Some are more preferred.
In the heat insulating material of the present invention, the heat-resistant inorganic paper preferably has an organic binder content of 0 to 55% by mass, more preferably 6 to 26% by mass, and 12 to 18% by mass. Some are more preferred.

本発明の断熱材において、耐熱性ペーパーの平均厚さは、０．２〜６ｍｍであることが好ましく、０．５〜３ｍｍであることがより好ましく、０．７１〜０．８５ｍｍであることがさらに好ましい。
なお、本出願書類において、耐熱性ペーパーの平均厚さは、ノギス又はマイクロメータで任意の８箇所の厚みを測定したときの算術平均値を意味する。 In the heat insulating material of the present invention, the average thickness of the heat-resistant paper is preferably 0.2 to 6 mm, more preferably 0.5 to 3 mm, and 0.71 to 0.85 mm. Further preferred.
In addition, in this application document, the average thickness of heat resistant paper means the arithmetic mean value when measuring thickness of arbitrary 8 places with a caliper or a micrometer.

本発明の断熱材において、耐熱性ペーパーの坪量は、２０〜４３０ｇ／ｍ２であることが好ましく、５０〜３５０ｇ／ｍ２であることがより好ましく、１００〜１２０ｇ／ｍ２であることがさらに好ましい。
なお、本出願書類において、耐熱性ペーパーの坪量（ｇ／ｍ２）は、ＪＩＳ Ｐ ８１２４の規定に基づいて算出される値を意味するものとする。 In the heat insulating material of the present invention, the basis weight of the heat-resistant paper is preferably 20~430g / m 2, it is more preferably from 50 to 350 g / m 2, a 100 to 120 g / m 2 Further preferred.
In addition, in this application document, the basic weight (g / m < 2 >) of heat resistant paper shall mean the value calculated based on prescription | regulation of JISP8124.

本発明の断熱材において、耐熱性ペーパーとして、具体的には、例えば、ニチアス（株）製ファインフレックス（登録商標）１３００ペーパーＴ、オリベスト（株）製ＲＡＰ−１１０Ｃ等を挙げることができる。   In the heat insulating material of the present invention, specific examples of the heat resistant paper include Fineflex (registered trademark) 1300 paper T manufactured by NICHIAS Corporation, and RAP-110C manufactured by Olivest Corporation.

本発明の断熱材は、耐熱性ペーパーを基材とするプリプレグを複数枚積層した状態で熱圧プレス成形されてなるものであり、上記プリプレグが厚さの薄い耐熱性ペーパーを基材とするものであることから、熱硬化性樹脂が均質に分散されたプリプレグが、熱圧成形時に熱ムラ（加熱温度のバラツキ）の発生を抑制しつつプレス成形されてなるものであると考えられる。
このために、本発明の断熱材は、同量の繊維状物および熱硬化性樹脂を含有する断熱材に比較して、精度の高い良好な加工性を有するとともに、優れた曲げ強度、靱性、厚さ精度等を発揮し得ると考えられる。 The heat-insulating material of the present invention is formed by hot press molding in a state where a plurality of prepregs having heat-resistant paper as a base material are laminated, and the prepreg is based on a heat-resistant paper having a thin thickness as a base material. Therefore, it is considered that the prepreg in which the thermosetting resin is homogeneously dispersed is press-molded while suppressing the occurrence of thermal unevenness (heating temperature variation) during hot-pressure molding.
For this reason, the heat insulating material of the present invention has excellent workability with high accuracy as compared with a heat insulating material containing the same amount of fibrous material and thermosetting resin, and has excellent bending strength, toughness, It is considered that the thickness accuracy can be exhibited.

本発明の断熱材において、耐熱性ペーパーに含浸される熱硬化性樹脂は、特に制限されない。
上記熱硬化性樹脂としては、例えば、熱硬化性フェノール樹脂、エポキシ樹脂、メラミン樹脂、ユリア樹脂、不飽和ポリエステル樹脂、アルキド樹脂、ポリウレタン樹脂、熱硬化性ポリイミド樹脂等の熱硬化性樹脂バインダーから選ばれる一種以上を挙げることができる。 In the heat insulating material of the present invention, the thermosetting resin impregnated in the heat-resistant paper is not particularly limited.
The thermosetting resin is selected from thermosetting resin binders such as thermosetting phenol resin, epoxy resin, melamine resin, urea resin, unsaturated polyester resin, alkyd resin, polyurethane resin, thermosetting polyimide resin, etc. One or more of these may be mentioned.

本発明の断熱材において、耐熱性ペーパーに含浸される熱硬化性樹脂が、熱硬化性樹脂バインダーを硬化剤や硬化促進剤の存在下に熱硬化してなるものである場合、熱硬化樹脂には、硬化剤や硬化促進剤も含まれるものとする。
硬化剤としては、ヘキサメチレンテトラミン等のアミン類や、フェノール樹脂硬化剤、有機過酸化物等の過酸化物等を挙げることができる。
硬化促進剤としては、リン系化合物、第３級アミン、イミダゾール、有機酸金属塩、ルイス酸、アミン錯塩などから選ばれる１種以上を挙げることができる。 In the heat insulating material of the present invention, when the thermosetting resin impregnated in the heat-resistant paper is obtained by thermosetting a thermosetting resin binder in the presence of a curing agent or a curing accelerator, Includes a curing agent and a curing accelerator.
Examples of the curing agent include amines such as hexamethylenetetramine, phenol resin curing agents, peroxides such as organic peroxides, and the like.
Examples of the curing accelerator include one or more selected from phosphorus compounds, tertiary amines, imidazoles, organic acid metal salts, Lewis acids, amine complex salts, and the like.

本発明の断熱材において、プリプレグは、耐熱性ペーパーに熱硬化性樹脂を含浸してなるものである。
本発明の断熱材において、断熱材の形成材料となるプリプレグは、繊維状物を３２〜６４質量％含むものであることが好ましく、３７〜４６質量％含むものであることがより好ましく、４０〜４４質量％含むものであることがさらに好ましい。
また、本発明の断熱材において、断熱材の形成材料となるプリプレグは、熱硬化性樹脂を、３６〜６８質量％含むものであることが好ましく、５４〜６３質量％含むものであることがより好ましく、５６〜６０質量％含むものであることがさらに好ましい。 In the heat insulating material of the present invention, the prepreg is formed by impregnating a heat-resistant paper with a thermosetting resin.
In the heat insulating material of the present invention, the prepreg serving as a heat insulating material forming material preferably contains 32 to 64% by mass of a fibrous material, more preferably 37 to 46% by mass, and 40 to 44% by mass. It is further preferable.
Moreover, in the heat insulating material of this invention, it is preferable that the prepreg used as the formation material of a heat insulating material contains 36-68 mass% of thermosetting resins, It is more preferable that it contains 54-63 mass%, 56- More preferably, the content is 60% by mass.

本発明の断熱材において、プリプレグは、粉末状の無機充填材を含むものであってもよい。
上記無機充填材としては、シリカ、炭酸カルシウム等から選ばれる一種以上を挙げることができる。
本発明の断熱材において、プリプレグが無機充填材を含むものであることにより、補強効果を発揮したり、密度、熱伝導率、クリープ性を容易に所望範囲に制御することができる。 In the heat insulating material of the present invention, the prepreg may contain a powdery inorganic filler.
Examples of the inorganic filler include one or more selected from silica, calcium carbonate, and the like.
In the heat insulating material of the present invention, when the prepreg contains an inorganic filler, the reinforcing effect can be exhibited, and the density, thermal conductivity, and creep properties can be easily controlled within a desired range.

本発明の断熱材において、断熱材の形成材料となるプリプレグは、無機充填材を０〜３２質量％含むものであることが好ましく、５〜２０質量％含むものであることがより好ましく、７〜１５質量％含むものであることがさらに好ましい。   In the heat insulating material of the present invention, the prepreg serving as a heat insulating material forming material preferably contains 0 to 32% by mass of an inorganic filler, more preferably 5 to 20% by mass, and more preferably 7 to 15% by mass. It is further preferable.

上記無機充填材は、プリプレグの作製時に、熱硬化性樹脂とともに耐熱性ペーパーに含浸させることにより、プリプレグ中に容易に含有させることができる。   The inorganic filler can be easily contained in the prepreg by impregnating the heat-resistant paper together with the thermosetting resin during the preparation of the prepreg.

本発明の断熱材において、プリプレグの平均厚みは、０．２〜６ｍｍであることが好ましく、０．５〜３ｍｍであることがより好ましく、０．７１〜０．８５ｍｍであることがさらに好ましい。
なお、本出願書類において、プリプレグの平均厚みは、ノギス又はマイクロメータで任意の８箇所の厚みを測定したときの算術平均値を意味する。 In the heat insulating material of the present invention, the average thickness of the prepreg is preferably 0.2 to 6 mm, more preferably 0.5 to 3 mm, and still more preferably 0.71 to 0.85 mm.
In addition, in this application document, the average thickness of a prepreg means the arithmetic mean value when measuring thickness of arbitrary 8 places with a caliper or a micrometer.

本発明の断熱材において、プリプレグの坪量は、３０〜６９０ｇ／ｍ２であることが好ましく、５０〜５５０ｇ／ｍ２であることがより好ましく、２１０〜２３０ｇ／ｍ２であることがさらに好ましい。
なお、本出願書類において、プリプレグの坪量（ｇ／ｍ２）は、１００ｃｍ四方の正方形状のプリプレグの質量（ｇ）から算出される値を意味するものとする。 In the heat insulating material of the present invention, the basis weight of the prepreg is preferably 30~690g / m 2, more preferably from 50~550g / m 2, further preferably 210~230g / m 2 .
In addition, in this application document, the basic weight (g / m < 2 >) of a prepreg shall mean the value computed from the mass (g) of a square prepreg of 100 cm square.

本発明の断熱材において、プリプレグは、例えば、熱硬化性樹脂（および必要に応じさらに無機充填材等）を満たした含浸容器中に所定時間耐熱性ペーパーを浸漬することにより作製することができる。   In the heat insulating material of the present invention, the prepreg can be produced, for example, by immersing the heat-resistant paper for a predetermined time in an impregnation container filled with a thermosetting resin (and, if necessary, an inorganic filler or the like).

図１は、本発明の断熱材の構成材料となるプリプレグの製造形態例を示す模式図である。
図１に示す例においては、耐熱性ペーパー１を巻回した状態で保持するホルダーＨから耐熱性ペーパー１をローラー等により引き出しつつ、熱硬化性樹脂２（および必要に応じさらに無機充填材等）を満たした含浸槽Ｔに浸漬して所定量の熱硬化性樹脂２（および必要に応じさらに無機充填材等）を含浸させ、その後、乾燥機Ｄで乾燥した後に、切断機Ｃで所定サイズに切断することにより、目的とするプリプレグ３を製造することができる。 FIG. 1 is a schematic diagram showing an example of a production form of a prepreg that is a constituent material of the heat insulating material of the present invention.
In the example shown in FIG. 1, the thermosetting resin 2 (and further an inorganic filler or the like if necessary) while pulling out the heat resistant paper 1 with a roller or the like from the holder H that holds the heat resistant paper 1 in a wound state. Is impregnated with a predetermined amount of thermosetting resin 2 (and further with an inorganic filler, if necessary), and then dried with a dryer D and then cut into a predetermined size with a cutting machine C. By cutting, the target prepreg 3 can be manufactured.

本発明の断熱材は、プリプレグを複数枚積層した状態で熱圧プレス成形されてなるものであり、上記プリプレグが厚みの薄い耐熱性ペーパーを基材とするものであることから、プリプレグも厚みが薄く熱硬化性樹脂が均質に分散されたものとなり、このために、本発明の断熱材は、以下に記述する熱圧成形時に熱ムラ（加熱温度のバラツキ）を抑制しつつ均一にプレス成形されてなるものであると考えられる。
上記理由により、本発明の断熱材は、同量の繊維状物および熱硬化性樹脂を含有する断熱材に比較して、良好な加工性を有するとともに、優れた曲げ強度、靱性、加工精度および厚さ精度等を発揮し得ると考えられる。 The heat insulating material of the present invention is formed by hot press molding in a state where a plurality of prepregs are laminated, and since the prepreg is based on a thin heat-resistant paper, the prepreg also has a thickness. As a result, a thin thermosetting resin is uniformly dispersed. For this reason, the heat insulating material of the present invention is uniformly press-molded while suppressing thermal unevenness (heating temperature variation) during hot-press molding described below. It is thought that
For the above reasons, the heat insulating material of the present invention has excellent workability and superior bending strength, toughness, processing accuracy, and heat insulating material containing the same amount of fibrous material and thermosetting resin. It is considered that the thickness accuracy can be exhibited.

本発明の断熱材は、上記プリプレグを複数枚積層した状態で熱圧プレス成形されてなるものである。
本発明の断熱材において、熱圧プレス成形されたプリプレグの積層枚数は特に制限されないが、本発明の断熱材は、厚さ１０ｍｍあたり、３〜２００枚のプリプレグが積層された状態で熱圧成形されてなるものであることが適当であり、１０〜２００枚のプリプレグが積層された状態で熱圧成形されてなるものであることがより適当であり、３０〜１００枚のプリプレグが積層された状態で熱圧成形されてなるものであることがさらに適当であり、３０〜８０枚のプリプレグが積層された状態で熱圧成形されてなるものであることが一層適当であり、４０〜８０枚のプリプレグが積層された状態で熱圧成形されてなるものであることがより一層適当であり、４０〜６０枚のプリプレグが積層された状態で熱圧成形されてなるものであることがより特に適当である。 The heat insulating material of the present invention is formed by hot press molding in a state where a plurality of the prepregs are laminated.
In the heat insulating material of the present invention, the number of laminated prepregs formed by hot press molding is not particularly limited, but the heat insulating material of the present invention is formed by hot pressure forming in a state where 3 to 200 prepregs are laminated per 10 mm thickness. It is appropriate that the prepreg is formed, and it is more appropriate that it is formed by hot pressing in a state where 10 to 200 prepregs are laminated, and 30 to 100 prepregs are laminated. It is more appropriate to be formed by hot pressing in a state, and it is more appropriate that 30 to 80 sheets of prepreg are laminated to form 40 to 80 sheets. It is even more suitable that the prepreg is laminated by hot pressing, and 40-60 prepregs are laminated by hot pressing. Ri is particularly suitable.

本発明の断熱材は、繊維状物を、３２〜６４質量％含むものであり、３７〜４６質量％含むものであることが好ましく、４０〜４４量％含むものであることがさらに好ましい。
本発明の断熱材において、耐熱性ペーパーが耐熱性を有する無機ペーパーである場合には、上記繊維状物は、当該無機ペーパーを構成する無機繊維等の繊維に相当し、耐熱性ペーパーが耐熱性を有する有機ペーパーである場合には、上記繊維状物は、当該有機ペーパーを構成する有機繊維等の繊維に相当する。
本発明の断熱材は、繊維状物を上記割合で含むものであることにより、良好な加工性、耐熱性、機械的強度、靱性等を発揮することができる。 The heat insulating material of the present invention contains a fibrous material in an amount of 32 to 64% by mass, preferably 37 to 46% by mass, and more preferably 40 to 44% by mass.
In the heat insulating material of the present invention, when the heat-resistant paper is an inorganic paper having heat resistance, the fibrous material corresponds to fibers such as inorganic fibers constituting the inorganic paper, and the heat-resistant paper is heat-resistant. In the case of an organic paper having the above, the fibrous material corresponds to a fiber such as an organic fiber constituting the organic paper.
The heat insulating material of the present invention can exhibit good processability, heat resistance, mechanical strength, toughness, and the like by including the fibrous material in the above ratio.

本発明の断熱材は、熱硬化性樹脂を、３６〜６８質量％含むものであり、５４〜６３質量％含むものであることが好ましく、５６〜６０質量％含むものであることがさらに好ましい。
本発明の断熱材において、熱硬化性樹脂は、繊維状物のバインダーとして機能するものであり、熱硬化性樹脂を上記範囲で含有することにより、耐熱性ペーパーに由来する繊維状物を好適に結着して、所望の耐熱性、機械的強度、靱性、厚さ精度等を発揮することができる。 The heat insulating material of the present invention contains 36 to 68% by mass of the thermosetting resin, preferably 54 to 63% by mass, and more preferably 56 to 60% by mass.
In the heat insulating material of the present invention, the thermosetting resin functions as a binder for the fibrous material, and by containing the thermosetting resin in the above range, the fibrous material derived from the heat-resistant paper is suitably used. By binding, desired heat resistance, mechanical strength, toughness, thickness accuracy, etc. can be exhibited.

本発明の断熱材は、上記プリプレグ１枚当たりの平均厚みが、０．０５〜３．０ｍｍになるまで熱圧プレス成形されてなるものであることが好ましく、０．０５〜０．２８ｍｍになるまで熱圧プレス成形されてなるものであることがより好ましく、０．１８〜０．２５ｍｍになるまで熱圧プレス成形されてなるものであることがさらに好ましく、０．２０〜０．２３ｍｍになるまで熱圧プレス成形されてなるものであることが一層好ましい。
本発明の断熱材は、熱圧プレス成形後のプリプレグ１枚当たりの平均厚みが上記範囲内にあることにより、プリプレグを所望厚みまで熱圧成形して、所定の耐熱性、機械的強度、靱性、厚さ精度等を発揮することができる。
なお、本出願書類において、上記熱圧成形後におけるプリプレグ１枚当たりの平均厚みは、ノギス又はマイクロメータで断熱材の任意の８箇所の厚みを測定して算術平均値Ｔ（ｍｍ）を求めるとともに、断熱材の断面を観察して積層数ｎを求めた上で、算出式Ｔ／ｎにより求めることができる。 The heat insulating material of the present invention is preferably formed by hot-pressing until the average thickness per prepreg becomes 0.05 to 3.0 mm, and becomes 0.05 to 0.28 mm. More preferably, it is formed by hot-pressing until it reaches 0.18 to 0.25 mm, more preferably 0.28 to 0.23 mm. It is more preferable that the material is formed by hot press molding.
The heat insulating material of the present invention has a predetermined heat resistance, mechanical strength, and toughness by hot pressing the prepreg to a desired thickness because the average thickness per prepreg after hot pressing is within the above range. The thickness accuracy can be exhibited.
In the present application documents, the average thickness per one prepreg after the above-described hot pressing is obtained by measuring the thickness of any 8 locations of the heat insulating material with a caliper or a micrometer to obtain the arithmetic average value T (mm). The number n of layers can be obtained by observing the cross section of the heat insulating material, and can be obtained by the calculation formula T / n.

また、本発明の断熱材は、熱圧成形前後におけるプリプレグの圧縮率が、１５〜５０％であるものが適当であり、１５〜３３％であるものがより適当であり、２１〜２９％であるものがさらに適当であり、２２〜２７％であるものが一層適当である。
本発明の断熱材は、熱圧プレス成形前後におけるプリプレグの圧縮率が上記範囲内にあることにより、プリプレグを所望厚みまで熱圧成形して、所定の耐熱性、機械的強度、靱性、厚さ精度等を容易に発揮することができる。 In addition, the heat insulating material of the present invention suitably has a prepreg compression rate of 15 to 50% before and after hot pressing, more preferably 15 to 33%, and 21 to 29%. Some are more appropriate, and 22-27% is more appropriate.
The heat insulating material of the present invention has a predetermined heat resistance, mechanical strength, toughness, thickness by hot pressing the prepreg to a desired thickness when the compression ratio of the prepreg before and after the hot press forming is within the above range. Accuracy and the like can be easily exhibited.

なお、本出願書類において、上記熱圧成形前後におけるプリプレグの圧縮率は、下記式により算出された値を意味するものとする。
圧縮率（％）＝（熱圧成形後のプリプレグ１枚あたりの平均厚み（ｍｍ）／熱圧成形に供したプリプレグ１枚の平均厚み（ｍｍ））×１００ In addition, in this application document, the compression rate of the prepreg before and behind the said hot-pressure shaping | molding shall mean the value calculated by the following formula.
Compression rate (%) = (Average thickness (mm) per prepreg after hot pressing) / Average thickness (mm) of one prepreg subjected to hot pressing) × 100

本発明の断熱材は、密度が、８００〜１６５０ｋｇ／ｍ３であるものが好ましく、９００〜１２５０ｋｇ／ｍ３であるものがより好ましく、１０００〜１１００ｋｇ／ｍ３であるものがさらに好ましい。
なお、本出願書類において、断熱材の密度は、縦１２０ｍｍ×横４０ｍｍ×得られた断熱材の厚さに切り出した試験片の寸法（ｍ３）および重量（ｋｇ）から求めた値を意味する。 The heat insulating material of the present invention preferably has a density of 800 to 1650 kg / m 3 , more preferably 900 to 1250 kg / m 3 , and still more preferably 1000 to 1100 kg / m 3 .
Note that in the present application, the density of the insulation material means a value calculated from the dimensions of the cut in the thickness of the vertical 120 mm × horizontal 40 mm × the heat insulating material obtained test pieces (m 3) and weight (kg) .

本発明の断熱材は、空気雰囲気下、２００℃で２４時間加熱したときに割れや欠けを生じない耐熱性を有するものであることが好ましく、２６０℃で２４時間加熱したときに割れや欠けを生じない耐熱性を有するものであることがより好ましい。   The heat insulating material of the present invention preferably has heat resistance that does not cause cracking or chipping when heated at 200 ° C. for 24 hours in an air atmosphere, and cracking or chipping when heated at 260 ° C. for 24 hours. It is more preferable to have heat resistance that does not occur.

本発明の断熱材は、熱伝導率が、０．２５Ｗ／（ｍ・Ｋ）以下であるものが好ましく、０．１８Ｗ／（ｍ・Ｋ）以下であるものがより好ましく、０．１２Ｗ／（ｍ・Ｋ）であるものがさらに好ましい。
本発明の断熱材は、熱伝導率が上記範囲内にあるものであることにより、所望の断熱性を発揮することができる。 The heat insulating material of the present invention preferably has a thermal conductivity of 0.25 W / (m · K) or less, more preferably 0.18 W / (m · K) or less, and 0.12 W / ( More preferably, m · K).
The heat insulating material of the present invention can exhibit a desired heat insulating property when the thermal conductivity is within the above range.

なお、本出願書類において、断熱材の熱伝導率は、ＪＩＳ Ａ １４１２−２：１９９９第２部 熱流計法ＨＦＭ法で測定した値を意味するものとする。   In addition, in this application document, the heat conductivity of a heat insulating material shall mean the value measured by JIS A 1412-2: 1999 2nd part heat flow meter method HFM method.

本発明の断熱材は、曲げ強度が、３０ＭＰａ以上であるものが好ましく、４５ＭＰａ以上であるものがより好ましく、７０ＭＰａ以上であるものがさらに好ましい。
なお、本出願書類において、曲げ強度は、ＪＩＳ Ｃ２２１０−１９７５の繊維強化樹脂の曲げ試験に基づいて測定した値を意味する。 The heat insulating material of the present invention preferably has a bending strength of 30 MPa or more, more preferably 45 MPa or more, and even more preferably 70 MPa or more.
In addition, in this application document, bending strength means the value measured based on the bending test of the fiber reinforced resin of JISC2210-1975.

本発明の断熱材は、プリプレグを複数枚積層した状態で熱圧プレス成形されてなるものであり、上記プリプレグが厚みの薄い耐熱性ペーパーを基材とするものであることから、プリプレグも厚みが薄く熱硬化性樹脂が均質に分散されたものとなり、このために、本発明の断熱材は、熱圧成形時に熱ムラ（加熱温度のバラツキ）を抑制しつつ均一にプレス成形されてなるものであると考えられる。
上記理由により、本発明の断熱材は、同量の繊維状物および熱硬化性樹脂を含有する断熱材に比較して、優れた曲げ強度発揮し得ると考えられる。 The heat insulating material of the present invention is formed by hot press molding in a state where a plurality of prepregs are laminated, and since the prepreg is based on a thin heat-resistant paper, the prepreg also has a thickness. A thin thermosetting resin is homogeneously dispersed. For this reason, the heat insulating material of the present invention is formed by uniformly press-molding while suppressing thermal unevenness (heating temperature variation) during hot-pressure molding. It is believed that there is.
For the above reasons, it is considered that the heat insulating material of the present invention can exhibit superior bending strength as compared with a heat insulating material containing the same amount of fibrous material and thermosetting resin.

本発明の断熱材は、ＪＩＳ Ｋ ６９１１により測定したときのシャルピー衝撃値が１０ｋＪ／ｍ２以上であるものが好ましく、２５ｋＪ／ｍ２以上であるものがより好ましく、２９ｋＪ／ｍ２以上であるものがさらに好ましい。
シャルピー衝撃値が上記範囲内にあることにより、十分な靱性を発揮することができる。 Those heat insulating material of the present invention is preferably one Charpy impact value as measured by JIS K 6911 is 10 kJ / m 2 or more, and more preferably not more 25 kJ / m 2 or more, 29kJ / m 2 or more Is more preferable.
When the Charpy impact value is within the above range, sufficient toughness can be exhibited.

本発明の断熱材は、ノギスにより任意の８箇所の厚さを測定したときに、厚さの差が±５ｍｍ以内である厚さ精度を有するものが好ましく、厚さの差が±３ｍｍ以内である厚さ精度を有するものがより好ましく、厚さの差が±１ｍｍ以内である厚さ精度を有するものがさらに好ましく、厚さの差が±０．１ｍｍ以内である厚さ精度を有するものが一層好ましく、厚さの差が±０．０５ｍｍ以内である厚さ精度を有するものがより一層好ましい。   The heat insulating material of the present invention preferably has a thickness accuracy that the thickness difference is within ± 5 mm when the thickness of any eight locations is measured with a caliper, and the thickness difference is within ± 3 mm. Those having a certain thickness accuracy are more preferable, those having a thickness accuracy within ± 1 mm are more preferable, and those having a thickness accuracy within ± 0.1 mm are more preferable. More preferably, the thickness difference is more preferably within ± 0.05 mm.

本発明の断熱材は、プリプレグを複数枚積層した状態で熱圧プレス成形されてなるものであり、上記プリプレグが厚みの薄い耐熱性ペーパーを基材とするものであることから、プリプレグも厚みが薄く熱硬化性樹脂が均質に分散されたものとなり、このために、本発明の断熱材は、熱圧成形時に熱ムラ（加熱温度のバラツキ）を抑制しつつ均一にプレス成形されてなるものであると考えられる。
上記理由により、本発明の断熱材は、マット状物をプレス成形してなる断熱材に比較して、加工時の精度に優れるとともに、優れた厚さ精度を発揮し得ると考えられる。 The heat insulating material of the present invention is formed by hot press molding in a state where a plurality of prepregs are laminated, and since the prepreg is based on a thin heat-resistant paper, the prepreg also has a thickness. A thin thermosetting resin is homogeneously dispersed. For this reason, the heat insulating material of the present invention is formed by uniformly press-molding while suppressing thermal unevenness (heating temperature variation) during hot-pressure molding. It is believed that there is.
For the above reasons, it is considered that the heat insulating material of the present invention is superior in accuracy during processing and can exhibit excellent thickness accuracy as compared with a heat insulating material obtained by press-molding a mat-like material.

本発明の断熱材は、良好な加工性を有しつつ、耐熱性、機械的強度、靱性等に優れ、加工精度および厚さ精度に優れた断熱材を提供することができる。   The heat insulating material of the present invention can provide a heat insulating material having excellent workability, excellent heat resistance, mechanical strength, toughness, etc., and excellent processing accuracy and thickness accuracy.

次に、本発明の断熱材の製造方法について説明する。
本発明の断熱材の製造方法は、耐熱性ペーパーに熱硬化性樹脂を含浸してなる、繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含み、平均厚みが０．２〜６ｍｍであるプリプレグを複数枚積層し、前記熱硬化性樹脂の硬化温度以上の温度雰囲気下、熱圧プレス成形することを特徴とするものである。 Next, the manufacturing method of the heat insulating material of this invention is demonstrated.
The manufacturing method of the heat insulating material of the present invention includes 32 to 64% by mass of a fibrous material and 36 to 68% by mass of a thermosetting resin, which are formed by impregnating a heat-resistant paper with a thermosetting resin, and the average thickness is 0. A plurality of prepregs each having a thickness of 2 to 6 mm are laminated and subjected to hot press molding in a temperature atmosphere equal to or higher than the curing temperature of the thermosetting resin.

本発明の製造方法において、耐熱性ペーパー、熱硬化性樹脂、プリプレグの詳細は、上述したとおりである。   In the production method of the present invention, details of the heat-resistant paper, the thermosetting resin, and the prepreg are as described above.

本発明の製造方法において、熱圧プレス成形に供するプリプレグの積層数（得られる断熱材を構成するプリプレグの枚数）は特に制限されないが、得ようとする断熱材の厚さ１０ｍｍあたり、３〜２００枚であることが好ましく、１０〜２００枚であることがより好ましく、３０〜１００枚であることがさらに好ましく、３０〜８０枚であることが一層好ましく、４０〜８０枚であることがより一層好ましく、４０〜６０枚であることが特に好ましい。   In the production method of the present invention, the number of prepregs to be subjected to hot press molding (the number of prepregs constituting the obtained heat insulating material) is not particularly limited, but is 3 to 200 per 10 mm of the thickness of the heat insulating material to be obtained. Preferably, the number is 10 to 200, more preferably 30 to 100, still more preferably 30 to 80, and still more preferably 40 to 80. 40 to 60 sheets are particularly preferable.

本発明の製造方法は、プリプレグ１枚当たりの平均厚みが、０．０５〜３．０ｍｍになるまで熱圧プレス成形するものであることが好ましく、０．０５〜０．２８ｍｍになるまで熱圧プレス成形するものであることがより好ましく、０．１８〜０．２５ｍｍになるまで熱圧プレス成形することがさらに好ましく、０．２０〜０．２３ｍｍになるまで熱圧プレス成形することが一層好ましい。   In the production method of the present invention, hot pressing is preferably performed until the average thickness per prepreg is 0.05 to 3.0 mm, and hot pressing is performed until 0.05 to 0.28 mm. More preferably, it is press-molded, more preferably hot-press press-molded until 0.18 to 0.25 mm, and even more preferably hot-press press-mold until 0.20 to 0.23 mm. .

本発明の製造方法は、成形後のプリプレグ１枚当たりの平均厚みが上記範囲内になるように熱圧成形することにより、加工性に優れ、所望の耐熱性、機械的強度、靱性、厚さ精度等を発揮する断熱材を作製することができる。   The production method of the present invention is excellent in workability by hot pressing so that the average thickness per prepreg after molding is within the above range, and desired heat resistance, mechanical strength, toughness, and thickness. A heat insulating material that exhibits accuracy and the like can be produced.

また、本発明の製造方法においては、熱圧成形前後におけるプリプレグの圧縮率が、１５〜５０％になるように熱圧プレス成形することが好ましく、１５〜３３％になるように熱圧プレス成形することがより好ましく、２１〜２９％になるように熱圧プレス成形することがさらに好ましく、２２〜２７％になるように熱圧プレス成形することが一層好ましい。
本発明の製造方法においては、成形前後におけるプリプレグの圧縮率が上記範囲内になるように熱圧プレス処理することにより、プリプレグを所望厚みまで熱圧成形して、加工性に優れ、所望の耐熱性、機械的強度、靱性、厚さ精度等を容易に発揮することができる。 Moreover, in the manufacturing method of this invention, it is preferable to hot-press press-mold so that the compression rate of the prepreg before and after hot-press molding may be 15 to 50%, and hot-press press molding so that it may become 15 to 33%. It is more preferable to perform hot press molding so as to be 21 to 29%, and it is more preferable to perform hot press molding so as to be 22 to 27%.
In the production method of the present invention, the prepreg is hot-pressed to a desired thickness by hot-pressing so that the compression ratio of the prepreg before and after molding is within the above range, and has excellent workability and desired heat resistance. , Mechanical strength, toughness, thickness accuracy, etc. can be easily exhibited.

本発明の製造方法において、熱圧プレス成形時の温度は、プリプレグを構成する熱硬化性樹脂の熱硬化温度以上の温度であり、例えば、１００〜２００℃であることが好ましく、１３０〜１８０℃であることがより好ましく、１４５〜１５５℃であることがさらに好ましい。   In the production method of the present invention, the temperature during hot press molding is a temperature equal to or higher than the thermosetting temperature of the thermosetting resin constituting the prepreg, and is preferably 100 to 200 ° C, for example, 130 to 180 ° C. It is more preferable that it is 145-155 degreeC.

本発明の製造方法において、熱圧プレス成形時の加圧時間は、プリプレグを構成する熱硬化性樹脂が熱硬化し得る時間であれば特に制限されず、例えば、３０分間以上であることが好ましく、６０分間以上であることがより好ましく、１２０分間以上であることがさらに好ましい。   In the production method of the present invention, the pressurization time during hot press molding is not particularly limited as long as the thermosetting resin constituting the prepreg can be thermoset, and is preferably, for example, 30 minutes or more. More preferably, it is 60 minutes or more, and further preferably 120 minutes or more.

本発明の製造方法においては、上記熱圧プレス成形後して得られた熱圧成形物を、必要に応じて更に機械加工してもよく、また、必要に応じて、適宜所定温度に加熱してアフターキュアを行ってもよい。   In the production method of the present invention, the hot-pressed product obtained after the hot-press pressing may be further machined as necessary, and appropriately heated to a predetermined temperature as necessary. After-curing.

図２は、本発明の製造方法の一形態例を示す模式図である。
図２に示す例においては、耐熱性ペーパーに熱硬化性樹脂を含浸してなるプリプレグ３を所望枚数枚積層して積層物Ｌを５個形成し、得られた５個のプリプレグの積層物Ｌを、各積層物間にスペーサーを介した状態でプレス機Ｐのプレス板間に積み重ねた上で、プリプレグを構成する熱硬化性樹脂の熱硬化温度以上の温度条件下、プリプレグ１枚当たりの平均厚みが所望厚みになるように加圧して熱圧プレスすることにより、目的とする断熱材４を得ることができる。
図２に示す態様においては、上記積層物Ｌを５個積み重ねた状態で熱圧プレス成形しているが、積層物Ｌは、通常、１〜２０個程度積み重ねた状態で熱圧プレス成形することができる。 FIG. 2 is a schematic view showing an example of the manufacturing method of the present invention.
In the example shown in FIG. 2, a desired number of prepregs 3 formed by impregnating thermosetting resin into heat-resistant paper are laminated to form five laminates L, and the resulting laminate L of five prepregs obtained. Are stacked between the press plates of the press P with a spacer interposed between the laminates, and the average per prepreg under the temperature condition equal to or higher than the thermosetting temperature of the thermosetting resin constituting the prepreg. The target heat insulating material 4 can be obtained by pressurizing and hot pressing so that the thickness becomes a desired thickness.
In the embodiment shown in FIG. 2, hot press molding is performed in a state where five of the laminates L are stacked, but the laminate L is usually hot press forming in a state of stacking about 1 to 20 stacks. Can do.

本発明の製造方法においては、このようにして断熱材を作製することができる。
本発明の製造方法で得られる断熱材の詳細は、本発明の断熱材の説明で述べたとおりである。 In the production method of the present invention, the heat insulating material can be produced in this way.
The details of the heat insulating material obtained by the production method of the present invention are as described in the description of the heat insulating material of the present invention.

本発明の製造方法は、プリプレグを複数枚積層した状態で熱圧プレス成形するものであり、上記プリプレグが厚さの薄い耐熱性ペーパーを基材とするものであることから、プリプレグ内に熱硬化性樹脂を均質に分散させることができるとともに、熱圧成形時における熱ムラ（加熱温度のバラツキ）の発生を抑制しつつプレス成形することができると考えられる。
このために、本発明の製造方法によれば、同量の繊維状物および熱硬化性樹脂を含有する断熱材に比較して、良好な加工性を有し、優れた曲げ強度、靱性、加工精度および厚さ精度等を発揮し得る断熱材を製造し得ると考えられる。 The production method of the present invention is a method in which a plurality of prepregs are laminated by hot press molding, and since the prepreg is based on a heat-resistant paper having a thin thickness, thermosetting is performed in the prepreg. It is considered that the heat-resistant resin can be uniformly dispersed and press molding can be performed while suppressing the occurrence of heat unevenness (heating temperature variation) during hot-pressure molding.
For this reason, according to the production method of the present invention, it has better workability and superior bending strength, toughness and processing compared to a heat insulating material containing the same amount of fibrous material and thermosetting resin. It is thought that the heat insulating material which can exhibit precision, thickness precision, etc. can be manufactured.

本発明によれば、良好な加工性を有しつつ、耐熱性、機械的強度、靱性等に優れ、加工精度および厚さ精度に優れた断熱材を提供するとともに、該断熱材を簡便に製造する方法を提供することができる。   According to the present invention, while providing good workability, it provides a heat insulating material excellent in heat resistance, mechanical strength, toughness, etc., excellent in processing accuracy and thickness accuracy, and easily manufactured the heat insulating material. A method can be provided.

次に、実施例を挙げて本発明を更に具体的に説明するが、これは単に例示であって、本発明を制限するものではない。   EXAMPLES Next, the present invention will be described more specifically with reference to examples. However, this is merely an example and does not limit the present invention.

（実施例１）
（１）プリプレグの作製
図１に示す装置を用い、ホルダーＨに巻き付けた耐熱性ペーパー１であるガラス繊維製ペーパー（平均厚さ０．７８ｍｍ、坪量１１０ｇ／ｍ２）をローラーで引き出しつつ、熱硬化性樹脂２であるレゾール型フェノール樹脂（熱硬化温度１５０℃）を満たした含浸槽Ｔに浸漬した後、乾燥機Ｄで６０〜１３０℃で乾燥し、次いで切断機Ｃで切断することにより、ガラス繊維製ペーパーに由来する繊維状物４２質量％、レゾール型フェノール樹脂５０質量％を含有する、平均厚さ０．８４ｍｍ、坪量２２０ｇ／ｍ２の縦２１１０ｍｍ、横１０５０ｍｍのプリプレグ３を複数枚作製した。 Example 1
(1) Preparation of prepreg Using the apparatus shown in FIG. 1, while pulling out glass fiber paper (average thickness 0.78 mm, basis weight 110 g / m 2 ), which is heat resistant paper 1 wound around holder H, with a roller, By dipping in an impregnation tank T filled with a resol type phenolic resin (thermosetting temperature 150 ° C.) which is thermosetting resin 2, drying at 60 to 130 ° C. with a dryer D, and then cutting with a cutter C A plurality of prepregs 3 having an average thickness of 0.84 mm, a basis weight of 220 g / m 2, a length of 2110 mm, and a width of 1050 mm, containing 42% by mass of a fibrous material derived from glass fiber paper and 50% by mass of a resol type phenol resin A sheet was produced.

（２）断熱材の作製
（１）で得たプリプレグ３を５７枚積層した積層物Ｌを５個作製し、得られた５個の積層物Ｌを、図２に示すように、各積層物間にスペーサーを介した状態でプレス機Ｐのプレス板間に積み重ねた上で、プリプレグ１枚当たりの平均厚みが０．２１ｍｍになるように、１５０℃の温度条件下、２時間熱圧プレス成形することにより、縦２０７０ｍｍ、横１０２０ｍｍ、厚さ１２ｍｍの断熱材４を得た。
得られた断熱材５は、ガラス繊維製ペーパーに由来する繊維状物４２質量％、レゾール型フェノール樹脂５０質量％を含有し、密度が１０５０ｋｇ／ｍ３、空気雰囲気下、２００℃で２４時間加熱したときに割れや欠けを生じない耐熱性を有し、熱伝導率が０．１２Ｗ／（ｍ・Ｋ）、曲げ強度が ６０ＭＰａ、ＪＩＳ Ｋ ６９１１により測定したときのシャルピー衝撃値が２９ｋＪ/ｍ２であり、ノギスにより任意の８箇所の厚さを測定したときに、厚さの差が０．２ｍｍ以内である厚さ精度を有し、切削加工したときに、割れや欠け等を生じることなく容易に加工し得る優れた加工性や加工精度を有するものであった。 (2) Production of heat insulating material Five laminates L in which 57 prepregs 3 obtained in (1) were laminated were produced, and the obtained five laminates L were each laminated as shown in FIG. After being stacked between the press plates of the press P with a spacer in between, hot press molding is carried out for 2 hours under a temperature condition of 150 ° C. so that the average thickness per prepreg is 0.21 mm. By doing so, the heat insulating material 4 of length 2070mm, width 1020mm, and thickness 12mm was obtained.
The obtained heat insulating material 5 contains 42% by mass of a fibrous material derived from glass fiber paper, 50% by mass of a resol type phenol resin, and has a density of 1050 kg / m 3 and is heated at 200 ° C. for 24 hours in an air atmosphere. And has a heat resistance that does not cause cracking or chipping, a thermal conductivity of 0.12 W / (m · K), a bending strength of 60 MPa, and a Charpy impact value of 29 kJ / m 2 as measured according to JIS K 6911. When measuring the thickness of any 8 locations with calipers, the thickness difference is within 0.2 mm, and there is no cracking or chipping when cutting. It had excellent processability and processing accuracy that could be easily processed.

（実施例２）
実施例１（２）の断熱材の作製工程において、プリプレグ３を１０５枚積層した積層物Ｌを５個作製し、プリプレグ１枚当たりの平均厚みが０．２１ｍｍになるように、１５０℃の温度条件下、２時間熱圧プレス成形した以外は、実施例１（２）と同様に熱圧プレス成形することにより、縦２０７０ｍｍ、横１０２０ｍｍ、厚さ２２ｍｍの断熱材４を得た。
得られた断熱材５は、ガラス繊維製ペーパーに由来する繊維状物４２質量％、レゾール型フェノール樹脂５０質量％を含有し、密度が１０５０ｋｇ／ｍ３、空気雰囲気下、２００℃で２４時間加熱したときに割れや欠けを生じない耐熱性を有し、熱伝導率が０．１２Ｗ／（ｍ・Ｋ）、曲げ強度が ６０ＭＰａ、ＪＩＳ Ｋ ６９１１により測定したときのシャルピー衝撃値が２９ｋＪ/ｍ２であり、ノギスにより任意の８箇所の厚さを測定したときに、厚さの差が０．２ｍｍ以内である厚さ精度を有し、切削加工したときに、割れや欠け等を生じることなく容易に加工し得る優れた加工性や加工精度を有するものであった。 (Example 2)
In the heat insulating material production process of Example 1 (2), five laminates L in which 105 prepregs 3 were laminated were produced, and the temperature was 150 ° C. so that the average thickness per prepreg was 0.21 mm. Under the conditions, the heat insulating material 4 having a length of 2070 mm, a width of 1020 mm, and a thickness of 22 mm was obtained by hot press molding in the same manner as in Example 1 (2) except that hot press molding was performed for 2 hours.
The obtained heat insulating material 5 contains 42% by mass of a fibrous material derived from glass fiber paper, 50% by mass of a resol type phenol resin, and has a density of 1050 kg / m 3 and is heated at 200 ° C. for 24 hours in an air atmosphere. And has a heat resistance that does not cause cracking or chipping, a thermal conductivity of 0.12 W / (m · K), a bending strength of 60 MPa, and a Charpy impact value of 29 kJ / m 2 as measured according to JIS K 6911. When measuring the thickness of any 8 locations with calipers, the thickness difference is within 0.2 mm, and there is no cracking or chipping when cutting. It had excellent processability and processing accuracy that could be easily processed.

（実施例３）
実施例１（２）の断熱材の作製工程において、プリプレグ３を１３３枚積層した積層物Ｌを５個作製し、プリプレグ１枚当たりの平均厚みが０．２１ｍｍになるように、１５０℃の温度条件下、２時間熱圧プレス成形した以外は、実施例１（２）と同様に熱圧プレス成形することにより、縦２０７０ｍｍ、横１０２０ｍｍ、厚さ２８ｍｍの断熱材４を得た。
得られた断熱材５は、ガラス繊維製ペーパーに由来する繊維状物４２質量％、レゾール型フェノール樹脂５０質量％を含有し、密度が１０５０ｋｇ／ｍ３、空気雰囲気下、２００℃で２４時間加熱したときに割れや欠けを生じない耐熱性を有し、熱伝導率が０．１２Ｗ／（ｍ・Ｋ）、曲げ強度が ６０ＭＰａ、ＪＩＳ Ｋ ６９１１により測定したときのシャルピー衝撃値が２９ｋＪ/ｍ２であり、ノギスにより任意の８箇所の厚さを測定したときに、厚さの差が０．３ｍｍ以内である厚さ精度を有し、切削加工したときに、割れや欠け等を生じることなく容易に加工し得る優れた加工性や加工精度を有するものであった。 (Example 3)
In the manufacturing process of the heat insulating material of Example 1 (2), five laminates L in which 133 prepregs 3 were stacked were prepared, and the temperature was 150 ° C. so that the average thickness per prepreg was 0.21 mm. Under the conditions, the heat insulating material 4 having a length of 2070 mm, a width of 1020 mm, and a thickness of 28 mm was obtained by hot press molding in the same manner as in Example 1 (2) except that hot press molding was performed for 2 hours.
The obtained heat insulating material 5 contains 42% by mass of a fibrous material derived from glass fiber paper, 50% by mass of a resol type phenol resin, and has a density of 1050 kg / m 3 and is heated at 200 ° C. for 24 hours in an air atmosphere. And has a heat resistance that does not cause cracking or chipping, a thermal conductivity of 0.12 W / (m · K), a bending strength of 60 MPa, and a Charpy impact value of 29 kJ / m 2 as measured according to JIS K 6911. When measuring the thickness of any 8 locations with calipers, the thickness difference is within 0.3 mm, and there is no cracking or chipping when cutting. It had excellent processability and processing accuracy that could be easily processed.

実施例１〜実施例３で得られた断熱材は、耐熱性ペーパーに熱硬化性樹脂を含浸してなるプリプレグを複数枚積層した状態で熱圧成形されてなるものであり、耐熱性ペーパーに由来する繊維状物と熱硬化性樹脂を所定割合で含有するものであることから、熱硬化性樹脂中に繊維状物を均質に含有し、良好な加工性を有しつつ、耐熱性、機械的強度、靱性、加工精度および厚さ精度等に優れるものであることが分かる。   The heat insulating materials obtained in Examples 1 to 3 are formed by hot pressing in a state in which a plurality of prepregs formed by impregnating a thermosetting resin into heat resistant paper are laminated. Since it contains the derived fibrous material and thermosetting resin at a predetermined ratio, the fibrous material is uniformly contained in the thermosetting resin, and has good workability, heat resistance, machine It can be seen that it has excellent mechanical strength, toughness, processing accuracy, thickness accuracy, and the like.

本発明によれば、良好な加工性を有しつつ、耐熱性、機械的強度、靱性、厚さ精度等に優れた断熱材を提供するとともに、該断熱材を簡便に製造する方法を提供することができる。   According to the present invention, while providing a heat insulating material excellent in heat resistance, mechanical strength, toughness, thickness accuracy and the like while having good workability, a method for easily manufacturing the heat insulating material is provided. be able to.

１ 耐熱性ペーパー
２ 熱硬化性樹脂
３ プリプレグ
４ 断熱材 DESCRIPTION OF SYMBOLS 1 Heat resistant paper 2 Thermosetting resin 3 Prepreg 4 Thermal insulation

Claims (9)

複数枚のプリプレグのみを積層した積層体からなる断熱材であって、
ガラス繊維の繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含み、
前記プリプレグが耐熱性ペーパーであるガラス繊維製ペーパーへの熱硬化性樹脂含浸物である
ことを特徴とする断熱材。 A heat insulating material made of a laminate in which only a plurality of prepregs are laminated ,
Including 32 to 64% by mass of glass fiber fibrous material and 36 to 68% by mass of thermosetting resin,
A heat insulating material characterized in that the prepreg is a thermosetting resin impregnated material for glass fiber paper which is heat resistant paper. 前記熱硬化性樹脂の含有割合が５４〜６３質量％であり、前記プリプレグ１枚当たりの平均厚みが０．０５〜３．０ｍｍである請求項１に記載の断熱材。   The heat insulating material according to claim 1, wherein a content ratio of the thermosetting resin is 54 to 63 mass%, and an average thickness per sheet of the prepreg is 0.05 to 3.0 mm. 前記プリプレグの積層数が、厚さ１０ｍｍあたり１０〜２００枚である請求項１または請求項２に記載の断熱材。   The heat insulating material according to claim 1 or 2, wherein the number of laminated prepregs is 10 to 200 per 10 mm in thickness. 熱伝導率が０．２５Ｗ／（ｍ・Ｋ）以下である請求項１〜請求項３のいずれかに記載の断熱材。   Thermal insulation is 0.25 W / (m * K) or less, The heat insulating material in any one of Claims 1-3. 密度が８００〜１６５０ｋｇ／ｍ３である請求項１〜請求項４のいずれかに記載の断熱材。 The heat insulating material according to any one of claims 1 to 4, wherein the density is 800 to 1650 kg / m 3 . 断熱材を製造する方法であって、
耐熱性ペーパーであるガラス繊維製ペーパーに熱硬化性樹脂を含浸してなる、ガラス繊維の繊維状物３２〜６４質量％と熱硬化性樹脂３６〜６８質量％とを含み、平均厚みが０．２〜６ｍｍであるプリプレグのみを複数枚積層し、
前記熱硬化性樹脂の硬化温度以上の温度雰囲気下、熱圧プレス成形する
ことを特徴とする断熱材の製造方法。 A method of manufacturing an insulation material,
Glass fiber paper, which is heat-resistant paper, is impregnated with a thermosetting resin and contains 32 to 64% by mass of a glass fiber fibrous material and 36 to 68% by mass of a thermosetting resin. Laminating only a plurality of prepregs of 2 to 6 mm,
A method for producing a heat insulating material, characterized by performing hot press molding in a temperature atmosphere equal to or higher than a curing temperature of the thermosetting resin. 前記熱硬化性樹脂の含有割合が５４〜６３質量％であり、前記プリプレグ１枚当たりの平均厚みが０．０５〜３．０ｍｍになるように熱圧プレス成形する請求項６に記載の断熱材の製造方法。   The heat insulating material according to claim 6, wherein the content of the thermosetting resin is 54 to 63% by mass and the hot press molding is performed so that the average thickness per sheet of the prepreg is 0.05 to 3.0 mm. Manufacturing method. 前記プリプレグを、得ようとする断熱材の厚さ１０ｍｍあたり１０〜２００枚となるように積層する請求項６または請求項７に記載の断熱材の製造方法。   The manufacturing method of the heat insulating material of Claim 6 or Claim 7 laminated | stacked so that it may become 10-200 sheets per 10 mm in thickness of the heat insulating material to obtain. 得られる断熱材の密度が８００〜１６５０ｋｇ／ｍ３である請求項６〜請求項８のいずれかに記載の断熱材の製造方法。 The density | concentration of the heat insulating material obtained is 800-1650 kg / m < 3 >, The manufacturing method of the heat insulating material in any one of Claims 6-8.
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